powercycle battery conditioner operation manual · powercycle battery conditioner . operation...
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MAN-000014-00 REV. B
Model # PCYFC-10kW-250A PCYFC-20kW-250A
PowerCycle Battery Conditioner Operation Manual
MAN-000014-00 REV. B
TABLE OF CONTENTS SPECIFICATIONS............................................................................................................................. 1 CYCLER CONTROLS AND USER INTERFACE ............................................................................. 3 OPERATING PROCEDURE ............................................................................................................. 4
TURN ON THE UNIT ...................................................................................................................... 4 PROGRAMING AND OPERATING THE CYCLER USING THE KEY PAD AND DISPLAY ........... 5
SELECT OPERATING MODE ....................................................................................................... 5 SETTING DISCHARGE CYCLE PARAMETERS ........................................................................... 6 SETTING THE CHARGE CYCLE PARAMETERS ......................................................................... 9 CYCLER SETTINGS .................................................................................................................... 12 STARTING A CYCLE ................................................................................................................... 14 STATUS SCREENS AVAILABLE FROM MAIN MENU................................................................ 16
PROGRAMMING AND OPERATING THE CYCLER FROM A PC ................................................ 18 GENERAL INFORMATION .......................................................................................................... 18 PORT LOCATION ........................................................................................................................ 18 CONNECTING TO THE CYCLER USING THE ACTISYS IR ADAPTER OR THE USB TO RS-232 ADAPTER ....................................................................................................................... 19 MAIN TAB .................................................................................................................................... 20 BATTERY/SYSTEMS TAB .......................................................................................................... 21 PROFILES TAB............................................................................................................................ 22 CHARGE SETTINGS TAB ........................................................................................................... 23 NETWORK TAB ........................................................................................................................... 24 ENERGY MANAGEMENT ........................................................................................................... 24 DISCHARGE SETTING TAB ....................................................................................................... 25
RECOMMENDED SETTINGS AND TYPICAL CYCLE REPRESENTATIONS ............................. 26 CHARGE PARAMETERS: ........................................................................................................... 26 DISCHARGE PARAMETERS ...................................................................................................... 27 CYCLE PARAMETERS SCREEN VARIABLES: .......................................................................... 28
TROUBLESHOOTING .................................................................................................................... 29 CONTACTING POWER DESIGNERS USA LLC ........................................................................... 30 SAFETY PRECAUTIONS ............................................................................................................... 30 EMC COMPLIANCE ....................................................................................................................... 30
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SPECIFICATIONS SPECIFICATIONS PCYFC-10kW-250A PCYFC-20kW-250A INPUT SPECIFICATIONS
Voltage 480VAC, 3-Phase ±10% Delta with Earth Ground
480VAC, 3-Phase ±10% Delta with Earth Ground
Current 13.8 A rms nominal 27.6 A rms nominal Input Protection Disconnect Rated On/Off Switch
OUTPUT SPECIFICATIONS Battery Voltage 24 - 48 V nominal 24 - 48 V nominal Discharge Current 250 A max 250 A max
Charge Current 400 A max @ 25 V 200 A max @ 50 V
800 A max @ 25 V 400 A max @ 50 V
Max Power 10 kW 20 kW OPERATING CONDITIONS
Temperature 0 - 40ºC Humidity 10-90% RH non-condensing
INTERFACE Communication User Interface
Keypad Display, InfraRed (IR), RS-232, Optional Ethernet
MECHANICAL Cooling Forced air (fans)
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SAVE THESE INSTRUCTIONS BEFORE ATTEMPTING TO OPERATE THE CYCLER, PLEASE READ THIS GUIDE CAREFULLY. This guide contains important instructions for PowerCycler series product line that shall be followed during installation and maintenance of the Cycler. Only qualified personnel should install, operate, or service this equipment.
Charger Drawer
Discharger Drawer
Air Filter
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Cycler Controls and User Interface The Cycler controls are found in the top section of the cabinet.
Disconnect Rated On/Off Switch: Used to turn the Cycler on and off
Keypad Display Assembly: User interface for programming, and operating the cycler, along with viewing the current status of the cycler.
LCD
RS-232 IR
Status LEDs
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OPERATING PROCEDURE Turn on the Unit
Energize the AC Mains.
Turn the On/Off switch to the On Position
4 8 V 2 0 0 A 0 1 / 0 1 / 0 5 1 2 : 0 0 : 0 0 C O N N E C T B A T T E R Y D I S P L A Y
If the LCD is not lit or if the above message is not displayed contact Power Designers for assistance.
Connect the battery to the Cycler
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Programing and Operating the Cycler Using the Key Pad and Display Select Operating Mode
Press the function (F) key to access the Main Menu . The following screen Set Cycler Operation Mode appears.
Note: if any other screen appears use the arrows (/) and scroll to the Set Cycler Operation Mode screen
M A I N M E N U : S E T C Y C L E R O P E R A T I O N M O D E E X I T E N T E R
Press Enter accesses the Set Cycler Operation Mode menu. Using the arrow (/) keys select from cycling, charging, or discharging modes, the Enter key will save the desired value.
O P E R A T I N G M O D E : C Y C L I N G E X I T E N T E R
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Setting Discharge Cycle Parameters The Discharge Cycle Parameters menu is accessed from the main menu.
Press the F key to access the Main Menu. Scroll down () to the Discharge Cycle Settings:
M A I N M E N U : D I S C H A R G E C Y C L E S E T T I N G S E X I T E N T E R
Pressing the Enter key will access the discharge menu. The various parameters required to set a discharge cycle are then displayed on successive screens.
Enter the nominal battery voltage.
N O M I N A L B A T T E R Y V O L T A G E 4 8 V E X I T E N T E R
Using the arrow (/) keys change the battery voltage, selecting from 24V, 36V, or 48V. Once the correct voltage is selected, pressing the Enter key will save the desired value.
Enter the nominal battery capacity (Ahrs).
N O M I N A L B A T T E R Y C A P A C I T Y 1 0 5 0 A H R S E X I T E N T E R
Using the arrow (/) keys select the battery capacity pressing the Enter key will save the desired value. Note the capacity is selectable in 10 Ahr increments
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Next, set discharge current through the discharge current setting screen.
S E T D I S C H A R G E C U R R E N T 2 1 0 A E X I T E N T E R
Using the arrow (/) keys set the desired discharge current, pressing Enter to save the desired value. Note the setting increments or decrements by 5 Set the maximum Depth of Discharge (DoD) percentage.
S E T M A X I M U M D E P T H O F D I S C H A R G E X X X % E X I T E N T E R
Using the arrow (/) keys set the discharge current pressing the Enter key saves the desired value. Note, DoD setting uses 1% increments. Note, when he desired % DoD is reached, the discharge cycle stops. Set the low cutoff voltage
L O W C U T O F F V O L T A G E V O L T S / C E L L 1 . 8 0 E X I T E N T E R
Using the arrow (/) keys set the low cutoff voltage setting, pressing the Enter key will save the desired value Note: the value uses 0.01V increment. When, if the battery voltage falls below the programmed low cut off voltage, the discharge cycle stops
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Set the maximum discharge time limit.
M A X I M U M D I S C H A R G E T I M E L I M I T 8 : 0 0 E X I T E N T E R
Using the arrow (/) keys set the maximum discharge time, the Enter key saves the desired value. When the maximum discharge time limit is exceeded, the discharge cycle stops Once programming is complete, the discharge cycle programming complete message appears.
D I S C H A G R E C Y C L E P R O G R A M M I N G C O M P L E T E E X I T
Pressing the EXIT key will return to the Main Menu.
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Setting the Charge Cycle Parameters
When setting the Charge Cycle parameters, the previously entered values from the Discharge cycle are retained. The charge parameters menu is accessed from the main menu.
Press the F key to access the Main Menu. Then scroll down () to the Charge Cycle Settings
M A I N M E N U : C H A R G E C Y C L E S E T T I N G S E X I T E N T E R
Pressing the Enter key will access the charge menu parameter settings. The various parameters required to set a charge cycle are then displayed on successive screens.
Enter the nominal battery voltage, using the arrow keys to select and Enter to save.
N O M I N A L B A T T E R Y V O L T A G E 4 8 V E X I T E N T E R
Enter the nominal battery capacity (Ahrs), using the arrow keys to select and Enter to save.
N O M I N A L B A T T E R Y C A P A C I T Y 1 0 5 0 A H R S E X I T E N T E R
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Set the charge current, using the arrow keys to select and Enter to save.
C H A R G E R A T E ( C C C U R R E N T ) 2 0 0 A E X I T E N T E R
Set the gassing volts per cell, using the arrow keys to select and Enter to save.
G A S S I N G ( C V ) V O L T A G E V O L T S / C E L L 2 . 3 7 E X I T E N T E R
Set the finish volts per cell to the desired value for 100% State of Charge (SoC) using the arrow keys to select and Enter to save.
F I N I S H V O L T A G E V O L T S / C E L L 2 . 5 5 E X I T E N T E R
Set the equalize volts per cell, typically high enough to cause an excess return, bringing gravity up to approximately 105 - 110% SoC, using the arrow keys to select and Enter to save.
E Q U A L I Z E V O L T A G E V O L T S / C E L L 2 : 5 8 E X I T E N T E R
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Enable Finish if desired, for the desired profiles, using the arrow keys to select and Enter to save. It is suggested that Finish be enabled every charge cycle when cycling a battery.
E N A B L E F I N I S H N O E X I T E N T E R
Enable Equalize if desired, for the desired profiles, using the arrow keys to select and Enter to save. It is suggested that the final charge cycle for a battery include Equalize.
E N A B L E E Q U A L I Z E N O E X I T E N T E R
After entering the desired Equalize function the charge cycle complete message is displayed. Pressing Exit will return to the main menu.
C H A R G E C Y C L E P R O G R A M M I N G C O M P L E T E E X I T
For more information on charge parameters, discharge parameters and graphic representation of typical cycles; refer to the section on typical settings following the programming section
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Cycler Settings
Cycler Settings are accessed from the Main Menu.
Press the F key to access the Main Menu. Use the arrow keys, scroll () down to the Cycler Settings
M A I N M E N U : C Y C L E R S E T T I N G S E X I T E N T E R
Pressing the Enter key will access the cycler settings. The various parameters required to set the order of discharge and/or charge cycles and the number of cycles are then displayed on successive screens.
S T A R T I N G C Y C L E : C H A R G E E X I T E N T E R
Use the arrow (/) keys to select the starting cycle charge or discharge, and Enter to save.
C Y C L E C O U N T 1 0 E X I T E N T E R
Use the arrow (/) keys set the number of cycles to complete, press enter to save. Note: In the Cycle Count, a Cycle is defined as a charge or a discharge.
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If a discharged battery is connected, and a charged battery is desired at the end of the test, the Cycle Start will be set to Charge and the Cycle Count will be set to an odd number. If a charged battery is connected, and a test is desired consisting of discharging the battery and then recharging, Cycle Start will be set to Discharge, and Cycle Count will be set to an even number There are two rest timers to allow the battery to cool following a charge or a discharge. The first timer is the rest following a charge cycle; while the second is the rest following a discharge cycle.
R E S T C H A R G E T I M E R 0 1 : 3 0 E X I T E N T E R
Use the arrow keys to set the desired time then, enter to save
R E S T D I S C H A R G E T I M E R 0 1 : 3 0 E X I T E N T E R
Use the arrow keys to set the desired time then, enter to save Once programming is complete, the charge cycle programming complete message will appear.
C Y C L E R S E T T I N G S P R O G R A M M I N G C O M P L E T E E X I T
Use the Exit key to return to the main menu
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Starting a Cycle
Connect the battery to the Cycler.
The screen will now show either Push Start to Begin Charge of Push Start to Begin Discharge. Pressing Start initiates the indicated cycle.
4 8 V 2 0 0 A 0 1 / 0 1 / 0 5 1 2 : 0 0 : 0 0 P U S H S T A R T T O B E G I N C H A R G E
Briefly a starting screen will appear, followed by a status screen indicating: cycle type, cycle number out of total programmed cycles, running time for the present cycle, voltage, amperes, temperature if being sensed, ampere hours, charging mode when charging, SoC or DoD
If the cycle is a charge cycle, the following screen showing the charge cycle details will appear.
C H A R G E Y / X H H : M M : S S V : X X X . X A : X X X X T : X X X F A H : X X X X M M % S O C : X X %
D I S C H Y / X H H : M M : S S V : X X X . X A : X X X X T : X X X F A H : X X X X % D O D : X X %
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To pause or stop the cycler press the stop button, at first a paused screen will appear. Pressing stop a second time will stop the cycles and return to the press start screen.
C H A R G E P A U S E D :
P U S H S T A R T T O R E S U M E
S T O P T O T E R M I N A T E
A L L P E N D I N G C Y C L E S
At the end of each cycle the number of completed cycles is displayed along with the rest timer, along with total A-hrs
C H A R G E Y O F X C O M P L E T E H H : M M : S S T E M P : X X X F A H R S : X X X X E X I T R E S T H H : M M : S S
After the last cycle completes a summary screen displaying the last cycle type is present.
C H A R G E X O F X C O M P L E T E H H : M M : S S T E M P : X X X F A H R S : X X X X E X I T
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Status Screens Available From Main Menu
The following are available by selecting the main menu, when the connect battery or push to start messages are displayed.
Cycle History
Using the arrow keys scroll to the cycle history display, press enter to view the history of up to the last 200 cycles, when finished press exit to return to the main menu.
M A I N M E N U : C Y C L E H I S T O R Y E X I T E N T E R
A typical cycle screen will show the cycle number, date, time, last voltage, and A-hrs
C H # 9 9 0 1 / 0 1 / 0 6 0 4 : 2 0 D R A W E R S : 1 V O L T : 5 8 . 6 H R S : 0 3 : 2 1 T E M P : 9 8 F A H R S : 5 6 2
The left and right arrows toggle between the two screens showing the details of the cycle. The up down arrows sequentially scroll through the cycles by number
C H # 9 9 0 1 / 0 1 / 0 5 0 4 : 2 0 A C T I V A T E D P R O F I L E S : T R C C C V F I E Q S T A T E : X X X X X X X X X X X X X X
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Finish / Equalize Next Cycle
This screen is used to force the next cycle to finish and equalize independent of other settings
Cycler Model
Displays the cycler model number
Lifetime Summary
Displays the total use of the cycle
Charge Profiles
Displays the settings for the charge segments selected for profile 0 and profile 1
Recovery Cycle for Sulfated Battery
This bring up a series of entries to set battery capacity, current, and timers to force a one-time very low current cycle to recover a severely sulfated or over discharged battery.
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Programming and Operating the Cycler From a PC General Information Programming and operating the cycler may be performed from a laptop connected to the cycler in addition to using the keypad. These ports may be used to down load the operating history of the cycler as well. PowerCharge DataLink User is required on the laptop, and is available at the following web location: http://powerdesigners.com/downloads/ You will also need either a USB to InfraRed (IR) adapter, if you choose to use the IR communications window on the cycler; or you will need a USB to RS-232 Male adapter.
Port Location Both communication ports are located on the front of the cycler
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Connecting to the Cycler Using the Actisys IR Adapter or the USB to RS-232 Adapter 1. With the IR adapter connected to the PC, First select the COM Port option
and second select the COM channel desired. Or with the USB to RS-232 adapter connected to the Cycler and PC, First select the COM Port option and second select the COM channel desired
2. From This Point Forward When Using the IR Adapter it is Necessary to Hold the Adapter in Front of the Cycle IR Window When Depressing Any Menu Button.
3. All Screens and Buttons Are the Same Using Either of the Ports 4. Pressing Connect followed by Quick Look Will Display the Present Settings
5. Pressing the Cycler Monitor Button Top Left Will Launch the Monitor Window
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Main Tab The Main tab has the following features and functions:
1. The top half of the screen shows the model serial number, current and power rating along with firmware revision, the available charger drawers also appear.
2. The bottom half shows the current operating state of the cycler, along with buttons that allow start, stop and a display refresh.
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Battery/Systems Tab The Battery/System tab provides the capability to change settings specific to all Power Designers products, therefore some settings are not used with the cycler. Those settings that are not used include:
Battery LowTemp Comp; Battery High Temp Comp; Battery High Comp Temp; Battery Max Temperature; Precharge Idle; Temp Sensor Detect;Use PT Params; and Ignore PT Faults
For settings that are used Power Designers recommends the user change only the following:
Battery Capacity, set to the desired Ahr rating; and Battery Voltage set to the desired battery voltage. Setting is accomplished by typing the value into the numeric field and then pressing the disk icon to save.
The remainder of the settings Power Designers recommends be left at the default values: Battery Auto Select Disabled Charge Auto Start Enabled Temperature Format Fahrenheit Daylight Saving Enabled Charge Profile Profile0 Profile Autoswitch Enabled
Note Default Values Are Restored by pressing the Default button followed by the Save Config button
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Profiles Tab The Profiles tab shows and adjusts the portions of the charge cycle that are applied to the battery for charging purposes. Power Designers recommends:
The following modes be checked for both profiles:, Trickle Mode, CV Mode, and Finish Mode. Finish Pulse should never be checked for either profile Equalize should be checked for profile 1 only. Profile 0 finish, should be Default, 23:00 and 08:00 for start and duration respectively and all days except Sunday checked. Profile 1 operation should start at 01:00 and have a 22:00 hour duration on Sunday only.
Note Default Values Are Restored by pressing the Default button followed by the Save Config button
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Charge Settings Tab The charge settings tab allows the current, voltage and timer; for each portion of the charge to be adjusted independently. For the cycler the High Pulse Time On and Pulse Time Off do not affect the operation. When working with this screen it is suggested that these steps be performed in this order:
1. Press the Default Button 2. Press Save Config button 3. Set Currents
a. Trickle 3% of battery capacity b. CC Charge Current 17% of battery capacity c. CV Finish Current 12 to 15% of battery capacity d. Finish Cahrge Current 5% of battery capacity e. Equalize Current 3% of battery capacity
4. Save currents by either pressing each disk icon, or by pressing the save config button
Recommended timers are: Trickle Charge Timer 12:00, CC Timer 06:15, CV Timer 03:00, Finish Timer 03:00, Equalize Timer 06:00 and Total Charge Timer 12:15. Recommended voltages are Trickle Cutoff Voltage 1.85, CV Charge Voltage 2.37, Finish Max Voltage 2.55 to 2.60, and Equalize to 2.60
Note Default Values Are Restored by pressing the Default button followed by the Save Config button
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Network Tab The network tab is only used with the Ethernet option. These settings are typically adjusted your IT department, based on the local server needs. These should only be changed by IT personnel.
Energy Management Power Designers recommends that the Energy Management features are left in the default disabled state when operating the cycler. Reducing the power will limit the effectiveness of the charging portion of the cycle.
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Discharge Setting Tab Discharge settings allow selection of the mode of operation; cycling, charging, or discharging; the starting cycle charge or discharge; as well as the discharge current recommended to be 20% of battery capacity; the depth of discharge recommended at 80; the discharge cutoff voltage recommendation of 1.7 VPC; the Discharge timer; and the rest timers following both discharge, and charge.
Timers should be used to allow the battery to cool between charge and discharge cycles. Note: In the Cycle Count, a Cycle is defined as a charge or a discharge. a discharged battery is connected, and a charged battery is desired at the end of the test, the Cycle Start will be set to Charge and the Cycle Count will be set to an odd number. If a charged battery is connected, and a test is desired consisting of discharging the battery and then recharging, Cycle Start will be set to Discharge, and Cycle Count will be set to an even number
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Recommended Settings and Typical Cycle Representations Charge Parameters:
Parameter Recommended Value 1 Trickle Current 3 A / 100 Ahrs 2 Trickle Voltage 1.75-1.95 VPC 3 CC Current 17 – 20A / 100 Ahrs 4 CV Voltage 2.37 VPC 5 CV Finish Current 12 - 15 A / 100 Ahrs 6 Finish Current 5 A / 100 Ahrs 7 Finish Voltage 2.55-2.60 VPC 8 Equalize Current 3 A / 100 Ahrs 9 Equalize Voltage 2.60 VPC
t
VB ; Ich
CC
Ich
VB
Trickle CC CV Finish
CV
CV Finish Current
Finish Voltage
Trickle Current
Trickle Voltage
Finish Current
80% S.O.C. 100% S.O.C.
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Discharge Parameters
Parameter Recommended Value 1 Discharge
Current 20A/100 Ahrs 2 Depth of Disch. 80% 3 Disch. Cutoff Volt 1.80
t
Discharge Current
VB
Cuttoff Voltage/*Discharge Timer
80% D.O.D.
-Idisch
100% D.O.D. VB ; - Idisch
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Cycle Parameters Screen Variables:
Parameter Recommended Value 1 Cycle Count As desired 2 Rest Charge
Time 1:00 to 8:00 to allow battery to cool
3 Rest Discharge Time
1:00 to 8:00 to allow battery to cool
t
Ich
VB
Cycle 1 Cycle 2 Cycle 3
Cutoff Voltage
Rest Charge Time
Idisch
Finish Voltage
Rest Disharge Time
VB ; Ich/Idisch
Charging Discharging Charging
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TROUBLESHOOTING There are a number of instances where the cycler will fault to protect itself from damage or to protect the battery. In these instances the fault is reset by pushing the stop button. Pressing the start button restarts the cycler. If the fault returns immediately or persists; contact Power Designers.
Power Designers will guide you through identifying the cause and corrective action.
DO NOT ATTEMPT TO SERVICE THE UNIT UNLESS INSTRUCTED TO BY POWER DESIGNERS.
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CONTACTING POWER DESIGNERS USA LLC
Power Designers USA LLC 4005 Felland Road, Suite 116
Madison, WI 53718 USA
www.powerdesigners.com
Main Office Phone: 608.231.0450 Main Office Fax: 608.231.9979
Service Department: 844.263.7050 Phones are answered between 8 a.m. and 4 p.m., Monday through Friday Central Time. After-hours calls are answered by voice mail and returned on the next business day. Questions and comments can also be submitted via fax or email.
SAFETY PRECAUTIONS
WARNING: Only qualified personnel should install and connect the cycler to the electrical supply
WARNING: Working with Batteries has inherent risks, Personnel Protective Equipment is requires, and must be defined by the end user company.
EMC Compliance: This device complies with Part 15 section 103 of FCC Rules as a digital device used exclusively as a power system in public utilities or industrial plants. Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference
that may cause undesired operation